System and method for ultrasonic detection and imaging

ABSTRACT

Systems and Methods are disclosed for the detection and imaging of ultrasonic energy. Embodiments of the invention utilize an array of ultrasonic sensors where data from each of the sensors are processed by RMS-to-DC conversion. In addition, embodiments of the invention output a contour map based on detected ultrasonic energy and blend at least one feature of the contour map with a feature of a visible image so that a blended image can be displayed to an operator. Furthermore, embodiments of the invention provide a system and method for repositioning an array of ultrasonic sensors with respect to target area or Unit Under Test (UUT) to facilitate a thorough and repeatable test.

TECHNICAL FIELD

This disclosure relates generally to data processing systems andmethods, and more particularly, but without limitation, to systems andmethods related to detection, imaging, and/or other processingassociated with ultrasonic energy.

BACKGROUND

A practical application for the detection and imaging of ultrasonicenergy is to locate, by inference, ultrasonic energy sources. Suchsources may be, for instance, a gas or fluid escaping from a pressurizedcontainer (in other words, a leak). Alternatively, ultrasonic energy maybe caused by a mechanical vibration, such as that caused by anexcessively-worn bearing or by missing teeth on a gear drive assembly.

Piezoelectric and other detectors are known for detecting ultrasonicenergy emissions. Known systems and methods utilizing such detectorshave many disadvantages, however. For instance, because of the signalfrequencies involved, known systems may utilize very high-speed samplingrates that increase the expense of data acquisition hardware.Furthermore, known detection systems do not provide user-friendlyoutputs. For example, such systems may not support imaging at all. Andknown systems that do provide imaging of the ultrasonic energy may notsufficiently relate the detected source of ultrasonic energy to thesurrounding environment in a way that allows for a targeted response tothe detection event. Moreover, known detection systems and methods maybe limited to a narrow Field-Of-View (FOV) without a structured way tofully screen a Unit Under Test (UUT) that occupies an area that is manytimes the size of the detector's FOV. Known hand-held detection systemsand methods are exemplary of this latter problem, relying on an operatorto wave the hand-held detection system with respect to the UUT in aneffort to provide an effective screen.

What is needed are systems and methods for detecting ultrasonic energythat reduce the cost of data acquisition, provide more useful outputs toa test operator, and enable more complete and repeatable ultrasonicenergy detection over a broad target area.

SUMMARY OF THE INVENTION

Embodiments of the invention seek to overcome one or more of thedisadvantages described above. For example, embodiments of the inventionutilize an array of ultrasonic sensors where data from each sensor inthe array are processed by RMS-to-DC conversion. An advantage of thisapproach is that it may eliminate the need for high-speedanalog-to-digital conversion (ADC) hardware as part of the datacollection channel. In addition, embodiments of the invention output acontour map based on detected ultrasonic energy and blend at least onefeature of the contour map with a feature of a visible or other image sothat a blended image can be displayed to an operator. Such a system andmethod may be more intuitive and useful to a user than a system thatmerely outputs an image based upon the ultrasonic energy alone.Furthermore, embodiments of the invention provide a system and methodfor repositioning an array of ultrasonic sensors with respect to targetarea or Unit Under Test (UUT) to facilitate a thorough and repeatabletest. As used herein, ultrasonic energy refers generally to vibrationsin the ultrasonic frequency range, for example at frequencies greaterthan about 20 kHz.

Embodiments of the invention provide a system configured to detectultrasonic energy including: an ultrasonic sensor array, the ultrasonicsensor array including a plurality of ultrasonic sensors; a processoroperably coupled to the ultrasonic sensor array; and a visible imagedetector module operably coupled to the processor, the system configuredto calculate a Root-Mean-Square (RMS) value associated with each of theplurality of ultrasonic sensors.

Embodiments of the invention provide a method for graphically displayingultrasonic energy including: receiving data from each of a plurality ofultrasonic sensors, the data based on Root-Mean-Square (RMS)calculation; building a contour map based on the received data;receiving a camera image; and blending at least one feature of thecontour map with at least one feature of the received camera image.

Embodiments of the invention provide a processor-readable medium havingstored thereon instructions for a method of generating a graphical userinterface (GUI), the method including: receiving data from each of aplurality of ultrasonic sensors, the data based on Root-Mean-Square(RMS) calculation; building a contour map based on the received data;receiving a visual camera image; blending at least one feature of thecontour map with at least one feature associated with the receivedvisual camera image to create a blended image; and displaying theblended image in a first portion of a display screen.

Embodiments of the invention provide a method for testing including:selecting a first view of a unit under test, the first view associatedwith a relative position between a first ultrasonic sensor array and theunit under test; selecting a first region, the first region beingassociated with a portion of the first view; calculating a contour mapbased on the first region; and recognizing at least one feature of thecontour map.

The invention will now be described with respect to exemplaryembodiments illustrated in the drawings and discussed in the detaileddescription.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of a functional architecture for an ultrasonicenergy detection system, according to an embodiment of the invention;

FIG. 2 is an illustration of the ultrasonic sensor array depicted inFIG. 1, according to an embodiment of the invention;

FIG. 3 is a block diagram of a functional architecture for theultrasonic sensor assembly 205, according to an embodiment of theinvention;

FIG. 4 is a perspective drawing of the ultrasonic sensor assembly 205,according to an embodiment of the invention;

FIG. 5A is a flow diagram for a graphical display method, according toan embodiment of the invention;

FIG. 5B is a flow diagram of a method for building a contour map,according to an embodiment of the invention;

FIG. 6 is an illustration of a graphical user interface (GUI), accordingto an embodiment of the invention;

FIG. 7 is an illustration of an ultrasonic sensor array positioned withrespect to a Unit Under Test (UUT), according to an embodiment of theinvention;

FIG. 8A is an illustration of a test environment, according to a firstembodiment of the invention;

FIG. 8B is an illustration of a test environment, according to a secondembodiment of the invention;

FIG. 9A is an illustration of a test environment, according to a thirdembodiment of the invention;

FIG. 9B is an illustration of a test environment, according to a fourthembodiment of the invention;

FIG. 10 is an illustration of a test environment, according to a fifthembodiment of the invention;

FIG. 11A is a flow diagram of a pattern generation method, according toan embodiment of the invention; and

FIG. 11B is a flow diagram of a testing method, according to anembodiment of the invention.

DETAILED DESCRIPTION

FIG. 1 is a block diagram of a functional architecture for an ultrasonicenergy detection system, according to an embodiment of the invention. Inthe illustrated embodiment, an ultrasonic sensor array 105 is coupled tothe power supply 110 and a data I/O module 115. The data I/O module 115is coupled to an ultrasonic transmitter 135, a motor controller 140, anda processor 120. The processor 120 may be or include a personalcomputer, microcomputer, microcontroller, or other processing element.Link 145 may be a Universal Serial Bus (USB) port, although othercommunication protocols may also be used. The processor 120 is coupledto video camera 130 and display 125. IOtech Personal Daq/50 Series USBData Acquisition Modules are suitable hardware choices for the data I/Omodule 115. The architecture may further include memory (not shown)coupled to the processor 120, the memory being configured to store dataand/or software that is executable by the processor 120.

Variations to the illustrated functional architecture are possible. Forexample, as indicated by dashed lines, the ultrasonic transmitter 135and the motor controller 140 are optional. In addition, in someembodiments, the video camera 130 may be coupled to the data I/O module115. Further, the video camera 130 could be adapted to capture stillimages (“snapshots”) instead of, or in addition to, video images.Moreover, the functional architecture illustrated in FIG. 1 may furtherinclude a laser or other range finder (not shown) coupled to theprocessor 120. Further, the functional architecture may include multipleinstances of any of the illustrated functional blocks. For instance,some embodiments may include multiple ultrasonic sensor arrays 105,multiple data I/O modules 115, multiple processors 120, and/or multiplemotor controllers 140. The couplings between functional blocksillustrated in FIG. 1 may be accomplished with any suitable wired orwireless interconnection protocol, according to design choice.

In operation, the ultrasonic sensor array 105 detects ultrasonic energyin response to ultrasonic energy sources (not shown) from a target areaor Unit Under Test (UUT). The ultrasonic sensor array 105 may includesignal processing modules (not shown) powered by the power supply 110.Processed ultrasonic data is coupled from the ultrasonic sensor array105 to the processor 120 via the data I/O module 115. Video Camera 130may be positioned to have a similar view of the ultrasonic source (notshown) as the ultrasonic sensor array 105. The processor 120 may beconfigured to further process the data received from the ultrasonicsensor array 105 and/or the video camera 130. The processor 120 may beadapted to display data derived from the ultrasonic sensor array 105,the video camera 130, or some combination or combinations thereof viathe display 125.

In embodiments lacking a natural ultrasonic source, the ultrasonictransmitter 135 may be applied. For example, to facilitate the detectionof defects, such as cracks or holes in the UUT, the ultrasonictransmitter 135 may be positioned inside of, or behind, the UUT so thatultrasonic energy from the ultrasonic transmitter 135 passing throughthe defect is detected by the ultrasonic sensor array 105.

In some instances, it may be desirable to change a relative positionbetween the UUT and the ultrasonic sensor array 105. In this respect, itmay be advantageous to move the position of the UUT. In otherembodiments, it may be advantageous to move the ultrasonic sensor array.To reposition either the UUT or the ultrasonic sensor array 105, themotor controller 140 may receive commands from the processor 120, forinstance to drive a stepper motor associated with tooling in the testenvironment. Exemplary embodiments of such repositioning will bedescribed in further detail with respect to FIGS. 9A, 9B, and 10.

FIG. 2 is an illustration of the ultrasonic sensor array depicted inFIG. 1, according to an embodiment of the invention. In the illustratedembodiment, an ultrasonic sensor array 105 may be or include atwo-dimensional rectangular array of ultrasonic sensor assemblies 205arranged in n rows by m columns, where n and m are any positive integer,where each row includes the same number of sensor assemblies 205 asother rows and where each column includes the same number of sensorassemblies 205 as other columns. The ultrasonic sensor array 105 couldinclude only a single row or a single column of sensor assemblies 205,thus forming a one-dimensional array.

The number of ultrasonic sensor assemblies 205, and relative positioningwith respect to each other, may be varied according to design choice.For example, in an alternative embodiment, a circular pattern or othertwo or three dimensional arrangement of sensor assemblies 205 could beutilized.

In alternative embodiments, one or more sensor assemblies 205 in theultrasonic sensor array 105 are sensitive to energy at other thanultrasonic frequencies.

FIG. 3 is a block diagram of a functional architecture for theultrasonic sensor assembly 205, according to an embodiment of theinvention. In the illustrated embodiment, the ultrasonic sensor assembly205 includes a detector 305 coupled to a Circuit Card Assembly (CCA)320. The detector 305 may be sensitive to a particular range ofultrasonic energy, for example a frequency range of approximately 38 to42 KHz, and may be a piezoelectric device. The detector 305 could alsobe sensitive to a broader frequency range, and filters (not shown) couldoptionally be applied to detect ultrasonic energy over a narrowerfrequency range.

The CCA 320 may include an amplifier 310 coupled to a true RMS-to-DCconverter 315. The output 325 of the true RMS-to-DC converter 315 may becoupled to the processor 120 via the data I/O module 115.

In operation, the detector 305 detects ultrasonic energy, providing ananalog signal (a varying voltage) to the amplifier 310. The amplifier310 amplifies the analog signal from the detector 305 and provides theamplified signal to the true RMS-to-DC converter 315.

Roughly stated, Root Mean Square (RMS) transformation (“transformation”being used interchangeably herein with “conversion” or “calculation”)produces a Direct Current (DC) equivalent of an Alternating Current (AC)voltage. True RMS-to-DC conversion is a statistical measure (thequadratic mean) of the magnitude of a varying quantity. For N measuredvoltages (v1, v2, . . . vN), the true RMS voltage (v_(RMS)) is given by:v _(RMS)=SQRT(1/N(v12+v22+ . . . +vN2)).In practical application, the N measurements must be taken rapidlyenough (as compared to the frequency of the signal) and over ameaningful window of time.

In alternative embodiments, approximations of the true RMS may be used.For example, a common approximation of the RMS value for a sinusoidalsignal is:v _(RMS)=(0.707)(vpeak), where vpeak=the peak voltage of an AC signal.

Other RMS approximations, such as the arithmetic mean or arithmeticmedian of the N measurements could also be used, although suchapproximated RMS-to-DC transformations would likely lead to lessaccurate results than the true RMS-to-DC conversion described above.

Preferably, RMS-to-DC conversions are performed for signals associatedwith each of the ultrasonic sensor assemblies over the same timeinterval. An output 325 associated with each of the ultrasonic sensorassemblies 205 provides a DC equivalent voltage to the data I/O module115. Analog Devices AD536A is a suitable true RMS-to-DC converter.

Other embodiments of the CCA 320 may include multiple amplifier stages.For example, the amplifier 320 may include a front-end preamplifier (notshown) and a variable-gain amplifier (not shown). One or more NationalSemiconductor LM386 low-voltage power amplifiers are suitable for theamplifier 310.

CCA 320 may include additional signal conditioning devices according todesign choice. Furthermore, the system could be partitioned so that thetrue RMS-to-DC converter 315 and/or the amplifier 310 is included withthe data I/O module 115 instead of the ultrasonic sensor assemblies 205.

FIG. 4 is a perspective drawing of the ultrasonic sensor assembly 205,according to an embodiment of the invention. In the illustratedembodiment, the ultrasonic sensor assembly 205 includes a cylindricalshroud 405 to encase the detector 305. The detector 305 and shroud 405may be affixed to a chassis 410, and CCA 320 may be mounted inside thechassis 410 and electronically coupled to the detector 305.

Other form factors for the shroud 405, chassis 410, and CCA 320 arepossible. For example, the shroud 405 may be of a hyperbolic, conical,hemispherical, or other shape that would facilitate focusing, filtering,or other conditioning of ultrasonic signals received by the detector305. The use of a shroud 405 is optional.

In an alternative embodiment, a single cylindrical, hyperbolic, conical,hemispherical, or other shroud (not shown) is adapted to focus, filter,or otherwise condition ultrasonic energy with respect to the entireultrasonic sensor array 105 rather than being present on each of theultrasonic sensor assemblies 205.

FIG. 5A is a flow diagram for a graphical display method, according toan embodiment of the invention. In the illustrated embodiment, afterinitialization step 505, the process advances to step 510 to receive theultrasonic sensor data, and also to step 525 to receive a video camerasignal. As described with reference to FIG. 3 above, the ultrasonicsensor data may be based on a true RMS-to-DC conversion of the signaloutput by the ultrasonic detector 305 or an approximation thereof.

After receiving the ultrasonic sensor data in step 510, the processadvances to step 515 to smooth data. The purpose of smoothing step 515is to reduce the effect of transient noise in the detection frequencyrange. In one embodiment, smoothing step 515 is performed via a simplemoving average calculation on the received data values. For example,smoothing step 515 may add the five most recent data values, then divideby five. Alternatively, a low-pass filter (LPF) (not shown), which maybe implemented in hardware or software, could be utilized to performsmoothing step 515.

Next, the process advances to step 520 to build a contour map. Anembodiment of step 520 is described below with reference to FIG. 5B.

Meanwhile, subsequent to receiving the video camera signal in step 525,the process advances to step 530 to zoom or scale (zoom/scale) an imageassociated with the video camera. The purpose of zooming/scaling step530 is to scale the Field Of View (FOV) of the video camera to thecontour map so that corresponding pixel locations on the video cameraimage and the contour map relate to the same physical locations of theUUT. The FOV of the video camera may be adjusted optically or viasoftware. In addition, zooming/scaling step 530 may be performedmanually or automatically. In automatic operation, step 530 may beinformed of the distance between the video camera and the UUT by aultrasonic range-finder, a laser range-finder, or other range-finder. Atransfer function may then be used to convert the distance data to avideo camera zoom value.

In step 535, the process blends data output from steps 520 and 530. Forexample, one or more features of the contour map resulting from step 520may be overlaid with one or more features of the scaled image resultingfrom step 530. An example of such a blended image is provided in theblended display window 615 of FIG. 6. Finally, in step 540, the blendedimage may be displayed. In sum, FIG. 5A illustrates that ultrasonic dataand video data may be separately processed before at least one featureof the processed ultrasonic data and the processed video data areblended. An advantage of a producing a blended image is that the sourceof the ultrasonic energy is spatially located with respect to thebroader context of a target test area or UUT.

Variations to the process illustrated in FIG. 5A are possible. Forexample, instead of or in addition to receiving a video camera signal instep 525, the process could receive a signal from an infrared (IR)camera (not shown) or other detector (not shown). In addition, in someembodiments, it may not be necessary to adjust the zoom in step 530 (forexample where the sensor array and video camera are always at a fixeddistance from the UUT). Moreover, smoothing data step 515 may be omittedaccording to application demands.

FIG. 5B is a flow diagram of a method for building a contour map,according to an embodiment of the invention. The illustrated process isan embodiment of building a contour map step 520 that is shown in FIG.5A. In the illustrated embodiment, the process begins by initializing atwo-dimensional (2D) matrix in step 545. Step 545 is informed by adesired resolution that translates to a first value (representing anumber of x positions) and a second value (representing a number of ypositions) in the matrix.

Next, in step 550, known data (z values) associated with the trueRMS-to-DC conversion (or approximation thereof) from each sensorassembly are associated with corresponding positions on the initialized2D matrix. Then, in step 555, the process determines unknown values, forexample by mathematical interpolation or extrapolation, which are alsoadded to the initialized matrix. Interpolation/extrapolation step 555can take into account the fact that the FOV of individual sensorassemblies may overlap at the UUT. Next, in step 560, the matrix isscaled based on a desired range of data in each dimension of the threedimensional matrix. For example, the scaling may be set for one or moreof the x, y, and z axes.

In step 565, a color ramp is created for data ranges of the z axis inthe matrix. For instance, where the z-axis scale varies from 0.0 to 1.0,a color ramp may specify that values between 0.0 and 0.7 are blue,values at 0.8 and 0.9 are yellow and orange, respectively, and values at1.0 are red. In step 570, the matrix may be colored according to thecolor ramp created in step 565 and then output to a display in step 570.

Variations to the illustrated process are possible. For example, in someembodiments, the determining unknown values step 555 may be omittedwhere resolution requirements do not require additional matrix datavalues. Scaling step 560 may likewise be omitted if not required by theapplication. Moreover, in some embodiments, pre-existing color ramps maybe used, eliminating the need to create a color map in step 565.

FIG. 6 is an illustration of a graphical user interface (GUI), accordingto an embodiment of the invention. In the illustrated embodiment, acontour map window 605 illustrates relative intensity of detectedultrasonic energy, peak intensity window 610 displays a peak intensitylocation on a plan view of the contour map, and a blended display window615 includes a feature of the contour map (in this case, cross-hairs 620associated with peak ultrasonic intensity) overlaid onto a color orgray-scale image from the video camera 130.

In an alternative embodiment (not shown) a blended window could includea blended image that includes a complete contour map (optionally atleast partially transparent) overlaid onto a video camera image. Otherblended variants are also possible.

FIG. 7 is an illustration of an ultrasonic sensor array positioned withrespect to a Unit Under Test (UUT), according to an embodiment of theinvention. As illustrated therein, an ultrasonic sensor array 105, shownin a profile view, includes multiple ultrasonic sensor assemblies 205and may also include the video camera 130 positioned on the ultrasonicsensor array 105. The advantage of co-locating the video camera 130 onthe ultrasonic sensor array 105 is to provide similar perspective in thesensor array 105 and the video camera 130 with respect to the UUT 705.Each of the sensor assemblies 205 may have a FOV of, for example, twelve(12) degrees. Accordingly, the fields of view of two or more sensorassemblies 205 may overlap at the UUT 705.

In embodiments of the invention, a laser or other range finder (notshown) may also be mounted to the sensor array 105 to measure a distanceto the UUT 705. Resulting distance information may be used, for example,to facilitate focusing the video camera 130 or performingzooming/scaling step 530 as discussed with reference to FIG. 5A.

The systems and methods described above with reference to FIGS. 1-7 maybe used together with any of the test environments discussed below withrespect to FIGS. 8A, 8B, 9A, 9B, or 10.

FIG. 8A is an illustration of a test environment, according to a firstembodiment of the invention. As shown therein, a hollow cubic cover 810having one open end may be raised or lowered in a vertical direction 815over a UUT 705 to enclose the UUT 705 during test. One or moreultrasonic sensor arrays 105 may be attached to one or more interiorsurfaces of the cubic cover 810. Accordingly, the UUT 705 can beinspected from one or more perspectives during a test procedure.Moreover, a benefit of the cubic cover 810 is that it shields backgroundnoise, thereby improving signal-to-noise ratio (SNR) at the one or moreultrasonic sensor arrays 105.

FIG. 8B is an illustration of a test environment, according to a secondembodiment of the invention. As shown therein, a hemispherical cover 820may be positioned over the UUT 705 along a vertical axis 815. An innersurface of the hemispherical cover 820 may include one or moreultrasonic sensor arrays 105. Like cubic cover 810, the hemisphericalcover 820 shields the UUT 705 from background noise during test, therebyimproving signal-to-noise ratio (SNR) at the one or more ultrasonicsensor arrays 105.

As described above with reference to FIGS. 8A and 8B, a test environmentmay utilize more than one ultrasonic sensor array 105. Systems utilizingmultiple sensor arrays 105 may be configured to switch between one ormore of the multiple sensor arrays 105 during test. Moreover, wheremultiple sensor arrays 105 are implemented, one or more of the sensorarrays 105 could be sensitive to energy outside of the ultrasonicfrequency range.

In embodiments of the invention, it may be advantageous to change theposition of the UUT 705 with respect to the ultrasonic sensor array 105.Exemplary material handling devices for accomplishing this areillustrated in FIGS. 9A, 9B, and 10.

FIG. 9A is an illustration of a test environment, according to a thirdembodiment of the invention. As illustrated therein, a UUT 705 may berotated about a vertical axis 910 using a carousel 905. Carousel 905 maybe driven by a stepper motor (not shown), which may be controlled bymotor controller 140. The benefit of such repositioning is thatdifferent views of the UUT 705 may be presented to the fixed sensorarray 705. Moreover, such changing views are under precise andrepeatable control.

FIG. 9B is an illustration of a test environment, according to a fourthembodiment of the invention. As shown therein, a UUT 705 is coupled to agimbal mount 925 having a base 915. The gimbal mount 925 facilitates thepositioning of the UUT about a vertical axis 920 and a horizontal axis930 to change the position of the UUT 705 with respect to a stationaryultrasonic sensor array 105. The gimbal mount 925 may be under thecontrol of the motor controller 140.

FIG. 10 is an illustration of a test environment, according to a fifthembodiment of the invention. As illustrated, an articulated arm 1005 mayinclude end effector 1010 adapted to position the ultrasonic sensorarray 105 with respect to the UUT 705. For example, the articulated arm1005 may allow for six (6) degree freedom of motion (x, y, z, roll,pitch, yaw) in changing the position of the ultrasonic sensor array 105with respect to the UUT 705. Either of the embodiments illustrated inFIG. 9A or 9B may be used in combination with the embodiment shown inFIG. 10. In addition, a conveyor system may be used as a materialhandling device to change the relative position of a UUT with respect toone or more ultrasonic sensor arrays 105 in the alternative or incombination with any of the embodiments described with reference toFIGS. 9A, 9B, or 10 above.

The methods discussed next with reference to FIGS. 11A and 11B can beused separately or together to enable a test environment.

FIG. 11A is a flow diagram of a pattern generation method, according toan embodiment of the invention. After initialization step 1105, theprocess receives a UUT part number in step 1110. The UUT part number maybe received in step 1110 based on manual input from an operator. Inother embodiments, step 1110 may be based on automated input, forexample a bar code scan, optical character recognition (OCR) scan, orother automated input.

Next, the process selects a first view (for example a predetermined planor perspective view of the UUT) in step 1115, then selects a firstregion (portion of the view) in step 1120. The process then calculatesat least one contour map in step 1125, for example using the processdescribed above with reference to FIG. 5B. In step 1130, the processextracts values from the one or more contour maps. In embodiments of theinvention, step 1130 may include manipulation of the extracted values,for instance selection of peak values or calculation of average valuesfrom the one or more contour maps. Patterns are created and stored instep 1135 based on the values extracted in step 1130. In conditionalstep 1140 the process determines whether all predetermined regions havebeen considered.

Where the result of conditional step 1140 is in the affirmative, theprocess advances to conditional step 1145 to determine whether allpredetermined views have been considered. Where the result ofconditional step 1140 is in the negative, the process selects a nextregion in step 1120.

Where the result of conditional step 1145 is in the negative, theprocess selects a next predetermined view in step 1115. Where the resultof conditional step 1145 is in the affirmative, the process terminatesin step 1150. Upon completion of the process illustrated in FIG. 11A,one or more patterns have been created for a particular UUT part number.The pattern generation process described above could be repeated for oneor more known good units and/or for one or more known defective units.

Variations to the process illustrated in FIG. 11A are possible. Forexample, some applications may only review a single view or only asingle region within any one or more views. In addition, in alternativeembodiments, calculation step 1125 may be eliminated where, for example,extraction step 1130 is based on a bit map image from the video camera.Data from other sensors, such as digital thermometers and/or digitalhygrometers may also be used in extraction step 1130. In addition, humanintelligence can be added to the patterns generated by the process inFIG. 11A. For example, different portions of the patterns can beassociated with part descriptors. Moreover, known “leaky” regions, suchas portions of the UUT that utilize temporary plugs during assembly andtest operations, can inform one or more patterns of the UUT created instep 1135.

FIG. 11B is a flow diagram of a testing method, according to anembodiment of the invention. After initialization step 1170, the processreceives a UUT part number in step 1172. The UUT part number may bereceived in step 1172 based on manual input from an operator. In otherembodiments, step 1172 may be based on automated input, for example abar code scan, optical character recognition (OCR) scan, patternrecognition, or other automated process.

Next, the process selects a first view (for example a predetermined planor perspective view of the UUT part number) in step 1174, then selects afirst region (portion of the view) in step 1176. Views and regionsselected in steps 1172 and 1174 correspond to views and regions selectedin steps 1115 and 1120, respectively. The process then calculates atleast one contour map in step 1178, for example using the processdescribed above with reference to FIG. 5B.

Then, in step 1180, the process selects a first pattern (includingreading the first pattern from memory) and performs a recognition taskin step 1182. Recognition task 1182 may be or include artificialintelligence and/or neural network approaches for analyzing data derivedfrom sensors. Such data may be analyzed on its own (in which caseselection step 1180 is not needed), or by comparison to one or morestored patterns. In a simple form, recognition step 1182 may simplycompare one or more peak measured values to a predetermined thresholdvalue. The result of recognition step 1182 may be or include, forexample, the identification of a leak, the precise location of a leak(by coordinates or with reference to a descriptive feature), anassessment of the flow rate and/or direction of a leak, and/or anestimate of the size of a hole in a pressurized UUT.

The process then advances to conditional step 1184 to determine whethera response is required. Where the result of conditional step 1184 is inthe affirmative, the process advances to response step 1186, which mayinclude, for example, logging or saving the results of recognition step1182 by UUT part number and serial number, notifying an operator, and/orfacilitating indicated rework or repair operations (not shown).Subsequent to step 1186, and where the result of conditional step 1184is in the negative, the process is promoted to conditional step 1188 todetermine whether all relevant patterns have been considered.

Where the result of conditional step 1188 is in the negative, theprocess selects a next pattern in step 1180. Where the result ofconditional step 1188 is in the affirmative, the process advances toconditional step 1190 to determine whether all regions have beenconsidered. Where the result of conditional step 1190 is in thenegative, the process selects a next region in step 1176. Where theresult of conditional step 1190 is in the affirmative, the processadvances to conditional step 1192 to determine whether all views havebeen considered. Where the result of conditional step 1192 is in thenegative, the process selects a next predetermined view in step 1174.Where the result of conditional step 1192 is in the affirmative, theprocess terminates in step 1294.

Variations to the process illustrated in FIG. 11B are possible. Forexample, some applications may only review a single view or only asingle region within any one or more views. In addition, in alternativeembodiments, recognition step 1182 may be further informed by primitiveimage or other comparisons to one or more stored bit map images.Alternatively, or in combination, recognition step 1182 may be based ona combination of more than one pattern, more than one region, and/ormore than one view.

The system described with reference to FIGS. 1-4 may be configured toperform one or more of the methods described with reference to FIGS. 5A,5B, 11A, and 11B. In addition, any one of the methods described withreference to FIGS. 5A, 5B, 11A, and 11B may be performed in hardware,software, or a combination of hardware and software. Moreover, themethods described with reference to FIGS. 5A, 5B, 11A, and 11B, or anyportion thereof, may be implemented by instructions that are stored oncomputer-readable medium so that the instructions can be read andexecuted by the processor 120.

INDUSTRIAL APPLICABILITY

The disclosed systems and method may be applicable to a wide variety ofapplications where it may be advantageous to detect, display orotherwise process data associated with ultrasonic energy. As describedabove, an ultrasonic signature may be associated with certain types ofdefects. Moreover, an ultrasonic source may be used in a testing ordiagnostic mode to uncover certain holes, cracks, voids, or otherdefects indicated by mechanical vibrations of mechanical components orsystems in the ultrasonic frequency range.

Accordingly, the systems and/or methods described herein may beapplicable for testing or diagnostics associated with, for instance:cylinders, transmissions, engine blocks, fuel tanks, fittings, valves,flanges, vehicles cabs, pump cavitations, missing gear teeth gear boxes,line blockage, steam traps, compressors, motors, pipes, flow direction,underground leaks, vacuum leaks, welds, substations, heat exchangers,seals, pump tanks, air brakes, gaskets, pressure leaks, electrical arcs,caulking, and/or junction boxes.

It will be apparent to those skilled in the art that variousmodifications and variations can be made to the disclosed systems andmethods. For instance, systems and/or methods could be implemented usingarithmetic mean, arithmetic average, or other approximation instead ofthe true RMS-to-DC translations described herein. In addition,combinations of the disclosed embodiments not specifically described arealso possible, for example those that utilize other sensor types insteadof, or in combination with, sensor types described herein. Accordingly,other embodiments will be apparent to those skilled in the art fromconsideration of the specification and practice of the disclosed systemand methods. It is intended that the specification and examples beconsidered as exemplary only, with a true scope being indicated by thefollowing claims and their equivalents.

1. A method for graphically displaying ultrasonic energy comprising: receiving data from each of a plurality of ultrasonic sensors that each comprise a Root-Mean-Square-Direct Current (RMS-DC) converter, the data based on a RMS-DC calculation; building a contour map based on the received data; receiving a camera image; and blending at least one feature of the contour map with at least one feature of the received camera image.
 2. The method of claim 1 further including smoothing the received data prior to the building.
 3. The method of claim 1 further including scaling the camera image prior to the blending.
 4. The method of claim 1 wherein building the contour map includes: initializing a matrix; inserting each of a plurality of known data values at positions in the matrix to create a contour map, each of the plurality of known data values associated with the RMS-DC calculation; scaling the contour map; and colorizing the contour map based on a color ramp.
 5. The method of claim 4 further including: determining additional data values via interpolation; and inserting the additional data values in the contour map prior to scaling the contour map.
 6. A processor-readable medium having stored thereon instructions for a method of generating a graphical user interface (GUI), the method comprising: receiving data from each of a plurality of ultrasonic sensors that each comprise a Root-Mean-Square-Direct Current (RMS-DC) converter, the data based on a RMS-DC calculation; building a contour map based on the received data; receiving a visual camera image; blending at least one feature of the contour map with at least one feature associated with the received visual camera image to create a blended image; and displaying the blended image in a first portion of a display screen.
 7. The processor-readable medium of claim 6, the method farther including displaying the contour map in a second portion of the display screen.
 8. The processor-readable medium of claim 6 wherein the at least one feature of the contour map is associated with a highest intensity on the contour map, the highest intensity related to a highest RMS-DC calculation value.
 9. A method for graphically displaying ultrasonic energy comprising: receiving data from each of a plurality of ultrasonic sensors, the data based on Root-Mean-Square (RMS) calculation; building a contour map based on the received data, the building of the contour map including initializing a matrix, inserting each of a plurality of known data values at positions in the matrix to create a contour map, each of the plurality of known data values associated with a Root-Mean-Square (RMS) calculation, scaling the contour map, and colorizing the contour map based on a color ramp; receiving a camera image; and blending at least one feature of the contour map with at least one feature of the received camera image.
 10. The method of claim 9 further including smoothing the received data prior to the building.
 11. The method of claim 9 further including scaling the camera image prior to the blending.
 12. The method of claim 9 further including: determining additional data values via interpolation; and inserting the additional data values in the contour map prior to scaling the contour map.
 13. A processor-readable medium having stored thereon instructions for a method of generating a graphical user interface (GUI), the method comprising: receiving data from each of a plurality of ultrasonic sensors, the data based on Root-Mean-Square (RMS) calculation; building a contour map based on the received data, the building of the contour map including initializing a matrix, inserting each of a plurality of known data values at positions in the matrix to create a contour map, each of the plurality of known data values associated with a Root-Mean-Square (RMS) calculation, scaling the contour map, and colorizing the contour map based on a color ramp; receiving a visual camera image; blending at least one feature of the contour map with at least one feature associated with the received visual camera image to create a blended image; and displaying the blended image in a first portion of a display screen.
 14. The processor-readable medium of claim 13, the method further including displaying the contour map in a second portion of the display screen.
 15. The processor-readable medium of claim 13 wherein the at least one feature of the contour map is associated with a highest intensity on the contour map, the highest intensity related to a highest RMS calculation value. 